0278772 EVINRUDE EXTENSION KIT ASSY.-5"LONGER 5" LONGER PARTS

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A (1)     9U-6198     Crankshaft Turning Tool     1    
A (2)     9U-7336     Housing     1    
5P-7305 Engine Turning Tool     1    
B     230-6284     Timing Pin (Camshaft)     1    
C     136-4632     Timing Pin (Crankshaft)     1    
268-1966 Adapter     1    
( 1 ) The Crankshaft Turning Tool is used on the front pulley.
( 2 ) This Tool is used in the aperture for the electric starting motor.Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston".
Illustration 1 g01335379
Typical example
Install Tooling (B) through hole (X) in camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston".
Illustration 2 g01335380
Remove plug (4) from the cylinder block. Install Tooling (C) into hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston".Note: Do not use excessive force to install Tooling (C) . Do not use Tooling (C) to hold the crankshaft during repairs.
Illustration 3 g01337898
Loosen nuts (6) on all rocker arms (7) . Unscrew adjusters (5) on all rocker arms (7) until all valves are fully closed.Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.
Apply sufficient pressure to fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Lock the fuel injection pump in this position. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove" for the correct procedure.
Illustration 4 g01335384
Typical example
Mark gears (1) , (2) and (3) in order to show alignment. Refer to Illustration 4.Note: Identification will ensure that the gears can be installed in the original alignment.
Remove fuel pump gear (3) . Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure.
Remove camshaft gear (1) . Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".
Remove idler gear (2) . Refer to Disassembly and Assembly, "Idler Gear - Remove and Install".Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
B     230-6284     Timing Pin (Camshaft)     1    
C     136-4632